Method And Apparatus For Selective Folding Or Redirecting

ABSTRACT

The present disclosure relates to a method for redirecting cut web products and/or rejecting cut web products. The method comprises advancing a plurality of cut web products along a first path and providing a redirecting or folding device for folding the plurality of cut web products and/or delivering the folded cut web products to a second path. Prior to reaching the folding device, the cut web products may be determined to be defective. The folding device can be accelerated, decelerated, or substantially stopped, such that a selected cut web product is not delivered to the second path, thereby rejecting the selected cut web product. The present disclosure additionally comprises an apparatus for redirecting and/or rejecting cut web products.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 11/724,699,filed Mar. 16, 2007, which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present disclosure relates to a method and apparatus for selectivefolding or redirecting of cut web products. More particularly, thepresent disclosure relates to a method and apparatus for high speedselective folding, redirecting, and/or rejecting of cut web products,such as diapers or catamenials.

BACKGROUND OF THE INVENTION

In some instances, there may be a desire to redirect cut web products ona high speed production line to a different production stream. In othercases, some cut products manufactured on a high speed production linemay contain defects. Several mechanisms exist for rejecting defectivecut web products, such as by diverting the defective cut web productsfrom the stream of cut web products that are of satisfactory conditionor good quality. One method that has been used to reject cut webproducts includes forcing the defective cut web products out of thestream of satisfactory products by using pneumatic air blasts, whichdivert the defective cut web products to a path that differs from thatfor the stream of satisfactory products. In such a method, the defectivecut web products are detected, and a pneumatic air blast forces thedefective cut web products out of the stream of quality products andinto a reject gap provided in the conveyor system or production line.Typically, the reject gap will be provided prior to subjecting the cutweb products to further processing, such as folding. Methods ofrejecting cut web products using pneumatic air blasts involve severaldisadvantages. Devices creating pneumatic air blasts require space.Similarly, extra space along the conveyor system is required to includea reject gap. A reject gap further involves system reliability issuesrelated to having a gap in the conveyor system, such as jamming.Additionally, pneumatic air blasts create excessive dust and noise.Furthermore, pneumatic air blasts are not entirely accurate and candivert more than solely the defective cut web product from the stream ofsatisfactory products. Also, the equipment to create, convey, regulate,and control the air blast is expensive to install and operate.

A similar method of rejecting cut web products includes using a vacuumto remove the defective cut web products from the stream of qualityproducts. The use of a vacuum, rather than pneumatic air blasts,involves similar disadvantages, such as requiring large amounts of spacefor the vacuum device, providing extra space along the conveyor systemfor the reject gap, creating excessive noise and dust, etc. Also, theadditional vacuum equipment and vacuum creation, control, andtransportation is expensive.

Another method of rejecting cut web products includes mechanicallyactivated switches, or flippers, that divert the defective cut webproducts to an alternative pathway, similar to the manner railwayswitches can divert trains to a different track. The mechanical switchesare commonly activated via a pneumatic or hydraulic cylinder or via anelectric motor. A typical configuration includes mechanical switchesthat pop up from the conveyor system and divert the defective cut webproducts below the switch towards an alternate pathway. Rejection ofdefective cut web products typically takes place before the cut webproducts are subjected to further processing, such as folding. As such,more space is required to create room for the mechanically activatedswitches and the alternate pathway. Thus, space consumption is adisadvantage to the mechanical switch method. Furthermore, theadditional mechanical switch equipment is expensive.

A method and apparatus for high speed selective folding, redirecting,and/or rejecting of cut web products that is compact may be desirable.Further, a method and apparatus that is accurate in removing only theselected cut web products from the stream of quality products may alsobe desirable. Further, a method and apparatus that creates less noiseand dust may be desirable. A method and system that does not need areject gap in the conveyor system also may be desirable. Additionally, asystem that uses existing equipment and control mechanisms to rejectproducts rather than adding equipment and ancillary devices to performthis task may be desirable.

SUMMARY OF THE INVENTION

The present disclosure, in an embodiment, is a method for rejectingdefective cut web products. A plurality of cut web products may advancealong a first path. A folding device may be provided for folding the cutweb products and delivering the folded cut web products to a secondpath. Some of the cut web products may be determined to be defective. Assuch, the folding device may be slowed down, substantially slowed down,or substantially stopped, such that the defective cut web product is notdelivered to the second path.

The present disclosure, in another embodiment, is an apparatus forselectively folding cut web products. The apparatus may include firstand second pathways for conveying cut web products, and a folding devicealong the first pathway for folding cut web products and delivering themto the second pathway. The folding device may include a tucker and adriver. The driver may contain programming to stop and restart thetucker and generally control the tucker.

While multiple embodiments are disclosed, still other embodiments of thepresent disclosure will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. As will be realized, theinvention is capable of modifications in various obvious aspects, allwithout departing from the spirit and scope of the present disclosure.Accordingly, the drawings and detailed description are to be regarded asillustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as formingthe present disclosure, it is believed that the invention will be betterunderstood from the following description taken in conjunction with theaccompanying figures, in which:

FIG. 1 is a side view of a selective folding apparatus in accordancewith an embodiment of the present disclosure.

FIG. 2 is a side view of a selective folding apparatus in accordancewith another embodiment of the present disclosure.

FIG. 3A is a front view of a folding mechanism of a selective foldingapparatus in accordance with another embodiment of the presentdisclosure.

FIG. 3B is a side view of a folding mechanism of a selective foldingapparatus in accordance with an embodiment of a folding mechanism ofFIG. 3A.

FIG. 4A is a side view of a folding mechanism of a selective foldingapparatus in accordance with yet another embodiment of the presentdisclosure.

FIG. 4B is a side view of the path followed by a folding mechanism of aselective folding apparatus in accordance with an embodiment of afolding mechanism of FIG. 4A.

FIG. 5A is a front view of a folding mechanism of a selective foldingapparatus in accordance with a further embodiment of the presentdisclosure.

FIG. 5B is a side view of a folding mechanism of a selective foldingapparatus in accordance with an embodiment of a folding mechanism ofFIG. 5A.

FIG. 6 is a front view of a drive mechanism of a folding mechanism of aselective folding apparatus in accordance with another embodiment of thepresent disclosure.

FIG. 7 is a front view of a drive mechanism of a folding mechanism of aselective folding apparatus in accordance with yet another embodiment ofthe present disclosure.

FIG. 8 is a front view of a drive mechanism of a folding mechanism of aselective folding apparatus in accordance with a further embodiment ofthe present disclosure.

FIG. 9 is a side view of a selective folding apparatus in accordancewith another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure relates to a novel and advantageous method andapparatus for selectively folding, redirecting, and/or rejecting a cutweb product. The method and apparatus of the present disclosure may beused with any suitable cut web product. Examples of cut web productsthat may be used with the present disclosure include, but are notlimited to, diapers, napkins, wet wipes, feminine care products, paperproducts, packaged products, etc. In some embodiments of the selectivefolding apparatus of the present disclosure, it may be desirable toredirect or reject a particular cut web product, for example when aparticular cut web product is determined to contain a defect. A cut webproduct alternatively may be redirected or rejected for any number ofreasons, including for any variety of reasons that the cut web productis unsatisfactory in any characteristic. In one embodiment, where it isdesirable to redirect or reject a particular cut web product, it mayfurther be desirable to allow the cut web product to pass or bypass afolding portion of the selective folding apparatus.

FIG. 1 illustrates an embodiment of a selective folding apparatusgenerally designated as numeral 5. Selective folding apparatus 5 mayinclude a first pathway 12 for cut web products 20, a second pathway 10for redirected or folded cut web products 22, a conveyor system 14, anda redirecting or folding mechanism 18 for folding cut web products 20and delivering folded cut web products 22 to second pathway 10. In someembodiments, selective folding apparatus 5 may further include a defectsensor 24, for detecting cut web products 20 that contain at least onedefect or otherwise do not meet satisfactory conditions.

In a further embodiment, selective folding apparatus 5 may include acutting device 16 for cutting a continuous length of web material intocut web products 20 prior to delivering cut web products 20 to firstpathway 12. In an embodiment shown in FIG. 1, the cutting device 16 isshown adjacent to first pathway 12. In other embodiments, cutting device16 need not be adjacent first pathway 12, and selective foldingapparatus 5 may comprise one or more intermediary paths or subject cutweb products 20 to further processes prior to entering first pathway 12.In yet other embodiments, selective folding apparatus 5 need not includecutting device 16 nor be attached to any other intermediary paths orfurther processing devices and may comprise a standalone apparatus.

As illustrated in FIG. 1, in an embodiment, cut web products 20 aredelivered, manually or mechanically, to first pathway 12. Cut webproducts 20 travel along first pathway 12 by means of conveyor system14. In an embodiment, conveyor system 14 comprises a belt and rollersystem. In other embodiments, conveyor system 14 may comprise any othersuitable mechanism, including but not limited to, a conveyor ortransport drum, for causing cut web products 20 to travel along firstpathway 12.

Cut web products 20 travel along first pathway 12 toward foldingmechanism 18. In an embodiment, folding mechanism 18 may selectivelycause cut web products 20 to be folded and may further cause the foldedcut web products 22 to be delivered to second pathway 10. In someembodiments, folded cut web products 22 may travel along second pathway10 by means of conveyor system 14 toward an exit of selective foldingapparatus 5. In further embodiments, folded cut web products 22 maytravel along other paths or be subjected to further processing, such astesting, stacking, packaging, etc. For example, in an embodiment, foldedcut web products 22 may travel along second pathway 10 toward a secondfolding mechanism, whereby folded cut web products 22 are folded,selectively folded, or redirected a second time. In a further example,folding mechanism 18 may fold, or selectively fold, cut web products 20across a first fold, wherein a first portion of cut web products 20 arefolded over a second portion of cut web products 20. The partiallyfolded cut web products may then be delivered to a second foldingmechanism, whereby the partially folded cut web products may be folded,or selectively folded, a second time, such that a third portion of cutweb products 20 is folded over the first/second folded portions of cutweb products 20, such as wherein a tri-folded cut web product isdesired. In alternative embodiments, cut web products 20 may pass by,and be selectively subjected to, any number of folding mechanisms, suchas three, four, or more folding mechanisms. In some embodiments,multiple folding mechanisms may be desired for any number of reasons,including but not limited to, directing cut web products 20 to alternatepathways, creating multiple folds in cut web products 20, rejecting cutweb products 20 based on specific characteristics, etc.

In an embodiment of selective folding apparatus 5, shown in FIG. 2, oneor more second pathways 82, 84, 86 may be provided for which cut webproducts 20 may be redirected from first pathway 12. In an embodiment, asingle pathway may be provided, while in other embodiments two or morepathways may be provided. In a further embodiment, any of cut webproducts 20 may be redirected to any of multiple second pathways 82, 84,86. Cut web products 20 may be redirected to any particular pathway forany number of reasons and is not limited to merely redirecting defectivecut web products or folded cut web products 22.

For example, in an embodiment, multiple second pathways 82, 84, 86 mayprovide separate pathways for folding cut web products 20 usingalternative methods of folding, such as, but not limited to, bi-folding,tri-folding, quad-folding, wrapping, rolling, or hand folding, or anycombination thereof, including providing one or more second pathways 82,84, 86 for any method of folding. In another embodiment, a selectednumber of cut web products 20 may be redirected to one or more secondpathways 82, 84, 86 for reasons relating to, but not limited to, thespeed of conveyor system 14, the relative line speed of first pathway 12compared with the speed of an apparatus used for folding, stacking,packaging, etc. on second pathways 82, 84, 86, or any othercharacteristic of selective folding apparatus 5 relating to the effectsof production line speeds on the resulting end product. In yet anotherembodiment, cut web products 20 traveling along first pathway 12 may beselected for redirection to one of the multiple second pathways 82, 84,86, such that half of cut web products 20 are redirected to a particularsecond pathway, a third of cut web products 20 are redirected to aparticular second pathway, a fourth of cut web products 20 are deliveredto a particular second pathway, or any other suitable fraction of cutweb products 20 traveling along first pathway 12 may be redirected to aparticular second pathway. As such, the product stream of cut webproducts 20 may be divided among more than one second pathway forfurther processing. Further processing in any of the multiple secondpathways 82, 84, 86 may include, but is not limited to, folding,testing, stacking, packaging, etc. Furthermore, the processing in anyparticular second pathway 82, 84, 86 may differ from the processing inany of the other multiple second pathways 82, 84, 86.

In an embodiment of selective folding apparatus 5, shown in FIG. 3A,folding mechanism 18 may include dual propeller-style tuckers 28, whichrotate in opposite directions, indicated by rotational arrows R1 and R2.In a further embodiment, folding mechanism 18 comprises dualpropeller-style tuckers 28, each propeller-style tucker having twoblades 30 each. In other embodiments, a fewer or greater number ofblades 30 may be provided on each propeller-style tucker 28. Forexample, propeller-style tucker 28 may comprise a single blade 30 or maycomprise three or more blades 30. In yet other embodiments, it isrecognized that a single propeller-style tucker 28 may be providedinstead of dual propeller-style tuckers 28. It is recognized furtherthat any suitable number of propeller-style tuckers 28, each with anysuitable number of blades 30, may be provided. The blades may beprovided in any desired shape or configuration.

As can be seen in FIG. 3B, propeller-style tuckers 28 may be phased suchthat blades 30 engage cut web products 20 as the cut web products 20travel along first pathway 12 and pass by folding mechanism 18. Blades30 may engage cut web products 20 for folding at any position. Forexample, in an embodiment, blades 30 may engage cut web products 20 at asubstantially center position, thereby folding cut web products 20substantially in half. However, it is recognized that blades 30 mayengage cut web products 20 in a position other than substantially at thecenter of cut web products 20, as may be done when cut web products 20will be folded more than a single time. Dual propeller style tuckers 28may further direct folded cut web products 22 to second pathway 10. Inan embodiment, folding mechanism 18 may direct cut web products 20 tosecond pathway 10 without folding cut web products 20. For example, inan embodiment, dual propeller-style tuckers 28 may direct cut webproducts 20 to second pathway 10 without folding cut web products 20 byredirecting a leading tip, or edge, of cut web products 20.

FIG. 4A illustrates a further embodiment of folding mechanism 18.Folding mechanism 18 may include tucker blade 32, shaft 34, fixed gear36, rotating gear 38, and drive belt 40. Rotating gear 38 may orbitfixed gear 36, as shown by rotational arrow R3. In a further embodiment,fixed gear 36 and drive belt 40 may cause rotating gear 38 to rotatearound its central axis. One end of tucker blade 32 may be fixed atsubstantially near the central axis of rotating gear 38, thereby causingtucker blade 32 to rotate with rotating gear 38. Other suitable meansmay be used for obtaining substantially the same effect and rotation oftucker blade 32, including, for example, replacing drive belt 40 with atleast one gear or gearbox. It is further recognized that more than onerotating gear 38 and tucker blade 32 may be provided to orbit fixed gear36.

FIG. 4B illustrates a path that may be followed by tucker blade 32 in anembodiment of folding mechanism 18 illustrated in FIG. 4A. Thedashed-line tucker blades represent positions that tucker blade 32 maybe located at some time throughout the orbit and rotation of rotatinggear 38. For ease of illustration, embodiments of shaft 34, fixed gear36, rotating gear 38, and drive belt 40 have been removed from FIG. 4B.

As can be seen in FIG. 4B, folding mechanism 18 may be phased such thattucker blade 32 engages cut web products 20 as the cut web products 20travel along first pathway 12 and pass by folding mechanism 18. Tuckerblade 32 may engage cut web products 20 for folding at any position. Forexample, in an embodiment, tucker blade 32 may engage cut web products20 at a substantially center position, thereby folding cut web products20 substantially in half. However, as previously stated, it isrecognized that tucker blade 32 may engage folding cut web products 20in a position other than substantially at the center of cut web products20, as may be done when cut web products 20 will be folded more than asingle time. Tucker blade 32 may further direct folded cut web products22 to second pathway 10. As previously described, in an embodiment,folding mechanism 18 may direct cut web products 20 to second pathway 10without folding cut web products 20. For example, in an embodiment,tucker blade 32 may direct cut web products 20 to second pathway 10without folding cut web products 20 by redirecting a leading tip, oredge, of cut web products 20.

Yet another embodiment of folding mechanism 18 can be seen in FIG. 5A.Folding mechanism may include tucker arm 50 and rotating arm 52. Tuckerarm 50 may be attached at one end to rotating arm 52. Rotating arm 52may rotate in place around a central axis of rotating arm 52, such as isillustrated by rotational arrow R4. In some embodiments, foldingmechanism 18 may include more than one rotating arm 52, as shown in FIG.5A. In further embodiments, rotating arm 52 may be a rotating bar,rotating plate, or rotating planetary gear system, or any other suitablestructure or configuration. It is recognized that any means for rotatingmay be used for, or in place of, rotating arm 52. As rotating arm 52rotates, tucker arm 50 may follow the path shown by the dashed-linetucker arms in FIG. 5A. The dashed-line tucker arms represent positionsthat tucker arm 50 may be located at some time throughout the orbit androtation of rotating arm 52. As can be seen in FIG. 5A, as tucker arm 50rotates with rotating arm 52, it may maintain a configuration wherein atany position during rotation, tucker arm 50 may be substantiallyparallel to any other position during rotation of tucker arm 50.

As can be seen in FIG. 5B, folding mechanism 18 may be phased such thattucker arm 50 engages cut web products 20 as the cut web products 20travel along first pathway 12 and pass by folding mechanism 18. Tuckerarm 50 may engage cut web products 20 for folding at any position. Forexample, in an embodiment, tucker arm 50 may engage cut web products 20at a substantially center position, thereby folding cut web products 20substantially in half. However, as previously stated, it is recognizedthat tucker arm 50 may engage folding cut web products 20 in a positionother than substantially at the center of cut web products 20, as may bedone when cut web products 20 will be folded more than a single time.Tucker arm 50 may further direct folded cut web products 22 to secondpathway 10. As previously described, in an embodiment, folding mechanism18 may direct cut web products 20 to second pathway 10 without foldingcut web products 20. For example, in an embodiment, tucker arm 50 maydirect cut web products 20 to second pathway 10 without folding cut webproducts 20 by redirecting a leading tip, or edge, of cut web products20.

Other suitable forms of folding mechanism 18 also may be appropriate foruse with some embodiments of selective folding apparatus 5 of thepresent disclosure. It is further recognized that the terms tucker,tucker blade, or tucker arm may refer to any suitable mechanism forengaging the cut web products 20 and causing the cut web products 20 tobe redirected and/or folded about an axis—typically, though notexclusively, an imaginary line—that defines two or more generallysymmetrical or asymmetrical portions of the cut web product 20.Furthermore, tucker blades 30 and 32 and tucker arm 50 may bemanufactured from any suitable materials such as, but not limited to,metal, metallic alloys, plastics, etc., or combinations thereof.

Folding mechanism 18 may comprise any drive mechanism 74 for operating atucker blade. In an embodiment of folding mechanism 18, illustrated inFIG. 6, drive mechanism 74 may be a line shaft drive mechanismcomprising main shaft 60, phasing gear box 62, disengagement clutch 64,and linking belt 68. Not all components of the line shaft drivemechanism shown in FIG. 6 are required, and some components may beeliminated from the line shaft drive mechanism without departing fromthe scope of the present disclosure, while others may be added orsubstituted.

In an embodiment, main shaft 60 may directly drive the folding mechanism18. In a further embodiment, main shaft 60 may indirectly drive thefolding mechanism 18. For example, in an embodiment, the main shaft 60may be linked to phasing gear box 62, which may phase the drivingrotation of main shaft 60 to align the engagement of folding mechanism18 with passing cut web products 20. A line shaft drive mechanism mayfurther include disengagement clutch 64. Disengagement clutch 64 maycause folding mechanism 18 to slow down, stop, and/or restart duringoperation of selective folding apparatus 5. That is, at any suitablemoment, disengagement clutch 64 may cause drive mechanism 74 to slowdown or stop, which may further prevent folding mechanism 18 fromengaging cut web product 20, folding cut web product 20, or deliveringcut web product 20 to second pathway 10. In other embodiments,disengagement clutch 64 may be replaced by other suitable mechanisms forslowing or stopping folding mechanism 18 from engaging cut web product20, folding cut web product 20, or delivering cut web product 20 tosecond pathway 10. Linking belt 68 may link main shaft 60, phasing gearbox 62, or disengagement clutch 64 with tucker blades 30 or 32 or tuckerarm 50. In an embodiment, linking belt 68 may be a belt or chain. Inalternative embodiments, linking belt 68 may be any suitable means forconnecting main shaft 60, phasing gear box 62, or disengagement clutch64 with tucker blades 30 or 32 or tucker arm 50, such that drivemechanism 74 is linked to tucker blades 30 or 32 or tucker arm 50, suchas via gears or gearboxes.

In another embodiment, illustrated in FIG. 7, drive mechanism 74 mayinclude motor 66 and linking belt 68. Motor 66, in a further embodiment,may be a servo motor for controlling the position of tucker blades 30 or32 or tucker arm 50 of folding mechanism 18. A servo motor may be usedto alter the speed of folding mechanism 18 quickly, includingaccelerating, decelerating, stopping, and restarting folding mechanism18 in a very short period of time. For example, a servo motor may beused to accelerate, decelerate, stop, and restart folding mechanism 18,including in a relatively short period of time, such as seconds orfractions of a second, such as milliseconds. In other embodiments aservo motor may be used to accelerate, decelerate, stop, and restartfolding mechanism 18 in any interval of time. Linking belt 68 may linkmotor 66 with tucker blades 30 or 32 or tucker arm 50. As previouslystated, linking belt 68 may be a belt or chain. In alternativeembodiments, linking belt 68 may be any suitable means for linking motor66 with tucker blades 30 or 32 or tucker arm 50, such that drivemechanism 74 is linked to tucker blades 30 or 32 or tucker arm 50, suchas via gears or gearboxes. Drive mechanism 74, illustrated in FIG. 7,may provide less driven inertia and lower momentum forces during slowingor stopping of folding mechanism 18 and may allow faster conveyor speedsand higher precision of folding mechanism 18 than the mechanismillustrated in FIG. 6.

In yet a further embodiment, shown in FIG. 8, linking belt 68 may beeliminated from drive mechanism 74. Motor 66, such as a servo motor, maybe linked directly to tucker blades 30 or 32 or tucker arm 50, such thatthe motor 66 directly controls tucker blades 30 or 32 or tucker arm 50.Drive mechanism 74, illustrated in FIG. 8, may provide even less driveninertia and lower momentum forces during slowing or stopping of foldingmechanism 18 and may allow even faster conveyor speeds and higherprecision of folding mechanism 18 than the mechanisms in FIG. 6 or 7.

Although folding mechanism 18 illustrated in FIGS. 6-8 includes dualpropeller-style tuckers 28, it is recognized that any tucker blade, orany other suitable structure, may be used in accordance with foldingmechanism 18 of the present disclosure. For example, folding mechanism18 may comprise any tucker blade system described above in combinationwith any drive mechanism 74 described above. Alternatively, foldingmechanism 18 may comprise any suitable tucker blade system incombination with any suitable drive mechanism.

In an embodiment of selective folding apparatus 5, cut web products 20are delivered, manually or mechanically, to first pathway 12. Cut webproducts 20 travel along first pathway 12 by means of conveyor system 14toward folding mechanism 18. In an embodiment, folding mechanism 18 mayselectively cause cut web products 20 to be folded and may further causethe folded cut web products 22 to be delivered to second pathway 10.That is, folding mechanism 18, in an embodiment, may cause some cut webproducts 20 to be folded and delivered to second pathway 10 whilefolding mechanism 18 allows other cut web products 20 to pass by withoutcausing the cut web products 20 to be folded or delivered to secondpathway 10.

Folding mechanism 18, in an embodiment, may allow some cut web products20 to pass without being folded and delivered to second pathway 10 byslowing down, such that folding mechanism 18 does not engage the cut webproducts 20 that have been selected to bypass folding mechanism 18. In afurther embodiment, folding mechanism 18 may allow some cut web products20 to pass without being folded and delivered to second pathway 10 bystopping, or pausing, the tucker blades or tucker arm in mid-operation,such that folding mechanism 18 is stopped in a position that avoidsengagement with cut web products 20 that have been selected to bypassfolding mechanism 18. After cut web product 20 bypasses foldingmechanism 18, folding mechanism 18 may be accelerated to operating speedor to another suitable speed. In an embodiment, folding mechanism 18 maybe accelerated to operating speed by the time the next consecutive cutweb product 20, which immediately follows the cut web product 20 thatwas selected to bypass folding mechanism 18, reaches folding mechanism18. In such an embodiment, folding mechanism 18 need not be disengaged,physically and/or mechanically, from an engaging position to anon-engaging position, thereby reducing the need for space and/or movingparts.

In a further embodiment, folding mechanism 18 may be accelerated, orsubstantially accelerated, such that the tucker blades or tucker arm maybe allowed to pass through first pathway 12 between consecutive cut webproducts 20, such that the tucker blades or tucker arm do not contactcut web products 20 that have been selected to bypass folding mechanism18. Subsequent to acceleration, folding mechanism 18 may reduce itsspeed to substantially the same speed as during prior operation, oranother suitable speed, such that the tucker blades or tucker arm maycontinue to pass through first pathway 12 between consecutive cut webproducts 20, thereby allowing consecutive cut web products 20 to bypassfolding mechanism 18. That is, folding mechanism 18 may be acceleratedor substantially accelerated, and then slowed or substantially slowed,such that the tucker blades or tucker arm are in a position that doesnot redirect cut web products 20 to second pathway 10. That is, foldingmechanism 18 may be accelerated or substantially accelerated, and thenslowed or substantially slowed, such that the tucker blades or tuckerarm are out of phase with cut web products 20 traveling along firstpathway 12. In an embodiment, folding mechanism 18 may be accelerated orsubstantially accelerated, and then slowed or substantially slowed, suchthat a single cut web product 20 is allowed to bypass folding mechanism18, and then folding mechanism 18 may be phased, by acceleration ordeceleration, back in accordance with cut web products 20 travelingalong first pathway 12, such that cut web products 20 are once againfolded and delivered to second pathway 10. In other embodiments, morethan a single consecutive cut web product 20 may be allowed to bypassfolding mechanism 18 before folding mechanism 18 is phased back inaccordance with cut web products 20.

In a further embodiment, folding mechanism 18 may be decelerated, orsubstantially decelerated, such that the tucker blades or tucker arm maybe allowed to pass through first pathway 12 between consecutive cut webproducts 20, such that the tucker blades or tucker arm do not contactcut web products 20 that have been selected to bypass folding mechanism18. Subsequent a deceleration, folding mechanism 18 may increase itsspeed to substantially the same speed as during prior operation, oranother suitable speed, such that the tucker blades or tucker arm maycontinue to pass through first pathway 12 between consecutive cut webproducts 20, thereby allowing consecutive cut web products 20 to bypassfolding mechanism 18. That is, folding mechanism 18 may be deceleratedor substantially decelerated, and then accelerated or substantiallyaccelerated, such that the tucker blades or tucker arm are in a positionthat does not redirect cut web products 20 to second pathway 10. Thatis, folding mechanism 18 may be decelerated or substantiallydecelerated, and then accelerated or substantially accelerated, suchthat the tucker blades or tucker arm are out of phase with cut webproducts 20 traveling along first pathway 12. In an embodiment, foldingmechanism 18 may be decelerated or substantially decelerated, and thenaccelerated or substantially accelerated, such that a single cut webproduct 20 is allowed to bypass folding mechanism 18, and then foldingmechanism 18 may be phased, by acceleration or deceleration, back inaccordance with cut web products 20 traveling along first pathway 12,such that cut web products 20 are once again folded and delivered tosecond pathway 10. In other embodiments, more than a single consecutivecut web product 20 may be allowed to bypass folding mechanism 18 beforefolding mechanism 18 is phased back in accordance with cut web products20.

In an embodiment, cut web products 20 are selected to bypass foldingmechanism 18 without being folded or delivered to second pathway 10 forany number of reasons, including but not limited to, defectiveness,testing purposes, etc., allowing cut web products 20 to pass to adifferent pathway other than second pathway 10. That is, cut webproducts 20 may be rejected, diverted, or sorted for any reason,including that cut web products 20 may be unsatisfactory in anycharacteristic or otherwise.

In some embodiments, selective folding apparatus 5 may further include adefect sensor 24 for detecting cut web products 20 that contain at leastone defect or otherwise do not meet satisfactory conditions. In anembodiment, defect sensor 24 may be located prior to folding mechanism18, such that defective cut web products are detected prior to reachingfolding mechanism 18. In such an embodiment, defect sensor 24 may belocated at any position prior to folding mechanism 18. Defect sensor 24need not be located near folding mechanism 18. Additionally, defectsensor 24 need not be located near cutting device 16, as illustrated inthe figures. In some embodiments, folding apparatus 5 may include morethan one defect sensor 24. Defect sensor 24 may be configured toevaluate each cut web product, or any desired subset, sampling, etc.thereof. For example, in an embodiment, it may be desirable to sample acertain fraction of cut web products, and then, if appropriate, to groupthe sampled product with those adjacent to it. By way of example only,if the defect sensor 24 detects every third cut web product 20, thatsensed product may be treated as representative of those that precedeand follow it.

In a further embodiment, cut web products 20 that contain at least onedefect or otherwise do not meet satisfactory conditions may be selectedto bypass folding mechanism 18, such that the defective cut web products72 (shown in FIG. 9) are not folded or delivered to second pathway 10.In some embodiments, defective cut web products 72 may be delivered toan alternate pathway or may be subjected to alternate processes, such astesting, destruction, other commercial or other uses, etc.

A further embodiment of selective folding apparatus 5, shown in FIG. 9,includes a location where cut web products 72, which have beendetermined to contain a defect or are unsatisfactory for any reason, aredelivered. In FIG. 9, cut web products 72 that have been determined tocontain a defect or are unsatisfactory for any reason are delivered toreject bin 70. In some embodiments, reject bin 70 may comprise aremovable bin where defective cut web products 72 are delivered ordisposed. In other embodiments reject bin 70 may be an incinerator, atrash compactor, or any other suitable device for disposal of defectivecut web products 72. In yet further embodiments, cut web products 72that have been determined to contain a defect or are unsatisfactory forany reason may be delivered to further paths or subjected to furtherprocesses, including but not limited to, testing, destruction, etc.

As illustrated in FIG. 9, in an embodiment, cut web products 20 aredelivered, manually or mechanically, to first pathway 12. Cut webproducts 20, travel along first pathway 12 by means of conveyor system14. As previously stated, in an embodiment, conveyor system 14 comprisesa belt and roller system. In other embodiments, conveyor system 14 maycomprise any other suitable conveyor means of causing cut web products20 to travel along first pathway 12. Cut web products travel along firstpathway 12 toward folding mechanism 18.

In an embodiment, folding mechanism 18 may selectively cause cut webproducts 20 to be folded and may further cause the folded cut webproducts 22 to be delivered to second pathway 10 or multiple secondpathways as described with reference to FIG. 2. In some embodiments,folded cut web products 22 may travel along second pathway 10 by meansof conveyor system 14 toward an exit of selective folding apparatus 5,as was described with reference to FIG. 1.

In some embodiments, however, where a cut web product 20 has beendetermined to contain a defect or is unsatisfactory for any reason,folding mechanism 18 may be caused to be slowed, including substantiallyslowed, in order to allow defective cut web product 72 to bypass foldingmechanism 18. In a further embodiment of selective folding apparatus 5,folding mechanism 18 may be caused to be nearly stopped, substantiallystopped, or stopped completely, to allow defective cut web product 72 tobypass folding mechanism 18. Folding mechanism 18 may allow defectivecut web product 72 to pass without folding defective cut web product 72.Similarly, folding mechanism 18 may allow defective cut web product 72to pass without delivering defective cut web product 72 to secondpathway 10. In an embodiment, folding mechanism 18 may be slowed,substantially slowed, or stopped, such that the tucker blade or tuckerarm does not come into contact with defective cut web product 72. Thatis, folding mechanism 18 may be slowed, substantially slowed, orstopped, such that the tucker blade or tucker arm is in a position thatdoes not block defective cut web product 72 from bypassing foldingmechanism 18.

In a further embodiment, folding mechanism 18 may be accelerated, orsubstantially accelerated, such that the tucker blades or tucker arm maybe allowed to pass through first pathway 12 between consecutive cut webproducts 20, such that the tucker blades or tucker arm do not contactdefective cut web products 72. Subsequent to acceleration, foldingmechanism 18 may reduce its speed to substantially the same speed asduring prior operation, or another suitable speed, such that the tuckerblades or tucker arm may continue to pass through first pathway 12between consecutive defective cut web products 72, thereby allowingconsecutive defective cut web products 72 to bypass folding mechanism18. That is, folding mechanism 18 may be accelerated or substantiallyaccelerated, and then slowed or substantially slowed, such that thetucker blades or tucker arm are in a position that does not redirectdefective cut web products 72 to second pathway 10. That is, foldingmechanism 18 may be accelerated or substantially accelerated, and thenslowed or substantially slowed, such that the tucker blades or tuckerarm are out of phase with cut web products 20 traveling along firstpathway 12. In an embodiment, folding mechanism 18 may be accelerated orsubstantially accelerated, and then slowed or substantially slowed, suchthat a single defective cut web product 72 is allowed to bypass foldingmechanism 18, and then folding mechanism 18 may be phased, byacceleration or deceleration, back in accordance with cut web products20 traveling along first pathway 12, such that cut web products 20 areonce again folded and delivered to second pathway 10. In otherembodiments, more than a single consecutive defective cut web product 72may be allowed to bypass folding mechanism 18 before folding mechanism18 is phased back in accordance with cut web products 20.

In a further embodiment, folding mechanism 18 may be decelerated, orsubstantially decelerated, such that the tucker blades or tucker arm maybe allowed to pass through first pathway 12 between consecutive cut webproducts 20, such that the tucker blades or tucker arm do not contactdefective cut web products 72. Subsequent to deceleration, foldingmechanism 18 may increase its speed to substantially the same speed asduring prior operation, or another suitable speed, such that the tuckerblades or tucker arm may continue to pass through first pathway 12between consecutive defective cut web products 72, thereby allowingconsecutive defective cut web products 72 to bypass folding mechanism18. That is, folding mechanism 18 may be decelerated or substantiallydecelerated, and then accelerated or substantially accelerated, suchthat the tucker blades or tucker arm are in a position that does notredirect defective cut web products 72 to second pathway 10. That is,folding mechanism 18 may be decelerated or substantially decelerated,and then accelerated or substantially accelerated, such that the tuckerblades or tucker arm are out of phase with cut web products 20 travelingalong first pathway 12. In an embodiment, folding mechanism 18 may bedecelerated or substantially decelerated, and then accelerated orsubstantially accelerated, such that a single defective cut web product72 is allowed to bypass folding mechanism 18, and then folding mechanism18 may be phased, by acceleration or deceleration, back in accordancewith cut web products 20 traveling on first pathway 12, such that cutweb products 20 are once again folded and delivered to second pathway10. In other embodiments, more than a single consecutive defective cutweb product 72 may be allowed to bypass folding mechanism 18 beforefolding mechanism 18 is phased back in accordance with cut web products20.

As stated previously, defective cut web product 72 may bypass foldingmechanism 18 and travel toward reject bin 70. In other embodiments,defective cut web product 72 may bypass folding mechanism 18 and traveltoward further paths or subjected to further processes, including butnot limited to testing, destruction, etc. After defective cut webproduct 72 bypasses folding mechanism 18, folding mechanism 18 may beaccelerated to operating speed or another speed. In an embodiment,folding mechanism 18 may be accelerated to operating speed by the timethe next consecutive cut web product 20 immediately following defectivecut web product 72 reaches folding mechanism 18.

Although the present disclosure has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An apparatus for rejecting defective cut web products, the apparatuscomprising: a first pathway for conveying cut web products; a secondpathway for conveying redirected cut web products; a folding mechanismcomprising a drive, a drive program, and a tucker blade connected withthe drive; wherein the drive program causes the drive to rotate thetucker blade to engage web products advancing along the first pathway todirect and fold cut web products to the second pathway; and wherein thedrive program slows the rotation of the tucker blade when a cut webproduct is determined to be defective such that defective cut webproduct is not directed to the second pathway.
 2. The apparatus of claim1, wherein the drive program stops the rotation of the tucker blade whena cut web product is determined to be defective such that defective cutweb product is not directed to the second path.
 3. The apparatus ofclaim 1, further comprising a defect sensor along the first pathwayprior to the folding mechanism that determines if a cut web product isdefective.
 4. The apparatus of claim 1, wherein the drive comprises aservo motor.
 5. The apparatus of claim 4, wherein the tucker blade isdirectly connected with the servo motor.
 6. The apparatus of claim 4,wherein the tucker blade is linked with the servo motor by at least oneof a belt drive, a gear, and a gearbox.
 7. The apparatus of claim 1,further comprising a rejected web product pathway for receivingdefective cut web products.
 8. The apparatus of claim 1, wherein thefolding mechanism further comprises: a fixed gear; a planetary gearhaving a central axis, wherein the planetary gear rotates about thecentral axis and orbits the fixed gear; and wherein the tucker blade isconnected with the planetary gear such that tucker blade orbits thefixed gear.
 9. The apparatus of claim 1, wherein the second pathwaycomprises two pathways, and wherein the folding mechanism causes a firstgroup of cut web products traveling along the first pathway to bedirected to one of the two pathways and a second group of cut webproducts traveling along the first pathway to be directed to the otherof the two pathways.
 10. An apparatus for rejecting defective cut webproducts, the apparatus comprising: a first pathway for conveying cutweb products; a second pathway for conveying redirected cut webproducts; a drive; a drive program; and a tucker blade having a distalportion and a proximal portion, wherein the proximal portion of thetucker blade is connected with the drive; and wherein the drive programcauses the drive to rotate the distal portion of the tucker blade aroundthe proximal portion to engage the distal portion with web productsadvancing along the first pathway to direct the cut web products to thesecond pathway; and wherein the drive program slows the rotation of thedistal portion of the tucker blade when a cut web product is determinedto be defective such that defective cut web product is not directed tothe second path.
 11. The apparatus of claim 10, wherein the driveprogram stops the rotation of the distal portion of the tucker bladewhen a cut web product is determined to be defective such that defectivecut web product is not directed to the second pathway.
 13. The apparatusof claim 10, further comprising a defect sensor along the first pathwayprior to the folding mechanism that determines if a cut web product isdefective.
 14. The apparatus of claim 10, wherein the drive comprises aservo motor.
 15. The apparatus of claim 14, wherein the proximal portionof the tucker blade is directly connected with the servo motor.
 16. Theapparatus of claim 14, wherein the proximal portion of the tucker bladeis linked with the servo motor by at least one of a belt drive, a gear,and a gearbox.
 17. The apparatus of claim 10, further comprising arejected web product pathway for receiving defective cut web products.18. The apparatus of claim 10, further comprising: a fixed gear; aplanetary gear having a central axis, wherein the planetary gear rotatesabout the central axis and orbits the fixed gear; and wherein theproximal portion of the tucker blade is connected with the planetarygear such that tucker blade orbits the fixed gear.